Acoustical ceiling tile

ABSTRACT

A ceiling tile includes a first layer and a second layer. The first layer includes first and second planar surfaces. The second layer is comprised of at least ten (10) percent fiberglass by weight and is joined adjacent to the first planar surface.

FIELD OF THE INVENTION

[0001] This invention relates to ceiling tiles and, in particular, to ahigh strength acoustical ceiling tile.

BACKGROUND

[0002] In the field of building construction, it is a common practice toinstall suspended ceilings in new or existing structures. Variousalternative structural systems and methods are used for hanging asupport frame at the approximate level of the desired ceiling and thenaffixing ceiling tiles, panels, or the like to the frame. Such framestypically are formed from channels that, in cross section, are in theshape of a “T”, an “I”, or other suitable shape. They may be made fromaluminum, steel, plastic or other materials that are suitable for theintended use. The tiles, panels and other surfacing materials commonlyare made from cellulose, plastic, glass, and other appropriatematerials.

[0003] Many such ceiling systems are known and in common use. However,many have shortcomings and difficulties that make them difficult toinstall, unattractive, or otherwise unacceptable in varying degrees.Therefore, improvements are desirable.

SUMMARY

[0004] In one aspect of the present invention, a ceiling tile isdisclosed. The ceiling tile includes a first layer and a second layer.The first layer includes first and second planar surfaces. The secondlayer is comprised of at least ten (10) percent fiberglass by weight andis joined adjacent to the first planar surface.

[0005] In another aspect of the present invention, an acoustical ceilingtile includes a foam panel and a first laminated layer. The foam panelhas first and second surfaces and is comprised of an open-cell melaminefoam. The first laminated layer is impregnated with fiberglass andjoined to the first surface of the foam panel.

[0006] In another aspect of the present invention, a ceiling tileincludes two opposed layers surrounding a foam core. The foam core ismade from an open-cell melamine foam. The two opposed layers comprise amaterial having at least ten (10) percent fiberglass by weight.

[0007] A more complete appreciation of the present invention and itsscope may be obtained from the accompanying drawings, that are brieflydescribed below, from the following detailed descriptions of presentlypreferred embodiments of the invention and from the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The invention may be more completely understood in considerationof the following detailed description of various embodiments of theinvention in connection with the accompanying drawings, in which:

[0009]FIG. 1 is a perspective view of an example embodiment of a ceilingtile according to the present disclosure.

[0010]FIG. 2 is a fragmented, perspective view of an example embodimentof a suspended ceiling grid usable with the ceiling tile of FIG. 1according to the present disclosure.

[0011]FIG. 3 is a cross sectional view of the ceiling grid of FIG. 2,taken along lines 3-3, with the ceiling tile of FIG. 1 suspended thereinaccording to the present disclosure.

[0012]FIG. 4 is a cross-sectional view of an example embodiment of theceiling tile of FIG. 1 according to the present disclosure.

[0013]FIG. 5 is a cross-sectional view of another example embodiment ofa ceiling tile according to the present disclosure.

[0014] While the invention is amenable to various modifications andalternative forms, specifics thereof have been shown by way of examplein the drawings and will be described in detail. It should beunderstood, however, that the intention is not to limit the invention tothe particular embodiments described. On the contrary, the intention isto cover all modifications, equivalents, and alternatives falling withinthe spirit and scope of the invention.

DETAILED DESCRIPTION

[0015] In the following description of preferred embodiments of thepresent disclosure, reference is made to the accompanying drawings thatform a part hereof, and in which is shown by way of illustrationspecific embodiments in which the disclosure might be practiced. It isunderstood that other embodiments may be utilized and structural changesmay be made without departing from the scope of the present invention.

[0016] In general, the present disclosure discusses a ceiling tile foruse in a suspended ceiling grid system. The ceiling tile is alightweight, multi-layer ceiling tile that has a high strength and otherdesirable properties.

[0017]FIG. 1 is a perspective view of a ceiling tile 10 usable in asuspended ceiling grid system. The ceiling tile 10 has many industrialapplications, but is especially suited for suspended ceilings thatinclude a framework with individual ceiling tiles suspended by flangesor lips in the framework.

[0018]FIG. 2 is a fragmented, perspective view of an example embodimentof such a suspended ceiling grid system 20. The suspended ceiling gridsystem 20 is an exposed grid system 22. The exposed grid system 22comprises first members 24 and second members 26. Generally, the firstmembers 24 and second members 26 are configured and arrangedperpendicular to each other to form the exposed grid system 26.Preferably, the first members are main runners 28. Preferably, thesecond members are cross runners 30.

[0019] The exposed grid system 22 further comprises third members 32.The third members are typically configured and arranged vertically andtypically are attached to another structure above the exposed gridsystem 22. Preferably, the third members 32 are hangers 34. Thesuspended ceiling grid system 20 generally defines rectangular areas 36.The rectangular areas 36 defined can be of any suitable dimension.Typically the rectangular areas are formed in standard sizes, forexample, twenty-four (24) inches by twenty-four (24) inches.

[0020]FIG. 3 is a cross-sectional view of a portion of the suspendedceiling grid system 20 taken along lines 3-3. Typically, the secondmembers 26 and cross runners 30 have a T-shaped cross-sectional area asillustrated in FIG. 3. However, any suitable cross-sectional shape canbe used. Likewise, the first members 24 and main runners 28 typicallyhave a T-shaped cross-sectional area, although not shown, but can haveany suitable cross-sectional shape. Preferably, the ceiling tile 10 fitswithin the rectangular area 36, described above, such that the ceilingtile 10 is supported by the first and second members 24, 26.

[0021]FIG. 4 is a cross-sectional area of the ceiling tile 10 of FIG. 1taken along line 4-4. Preferably, the ceiling tile 10 includes a firstlayer 101, a second layer 102, and a third layer 103. In general, thesecond layer 102 is sandwiched, or placed between, the first layer 101and the third layer 103. Preferably, the first layer 101 is attached,bonded, or joined to the second layer 102. Likewise, the third layer 103is attached, bonded, or joined to the second layer 102 to form anunified ceiling tile 10.

[0022] In the example embodiment shown in FIG. 4, the first layer 101 isattached to the second layer 103 by a fourth layer 104. Preferably, thefourth layer 104 comprises an adhesive like material. Likewise, thethird layer 103 is attached to the second layer 102 by a fifth layer105. Preferably, the fifth layer 105 comprises an adhesive likematerial. It is noted that the first layer 101 could be chemicallybonded to the second layer 102 without the need for the fourth layer104. Likewise, the third layer 103 could be chemically bonded to thesecond layer 102 without the need for the fifth layer 105.

[0023] Typically, the second layer 102 comprises a foam core 110 andincludes first and second planar surfaces 112, 114. One example ofsuitable foam core 110 is preferably made from an open-cell melaminematerial, such as WILLTEC® foam, available from Illbruck ArchitecturalProducts in Minneapolis, Minn. Of course, any suitable material for thesecond layer 102 can be used. The first layer 101 is joined adjacent thefirst surface 112 of the second layer 102 and the third layer 103 isjoined adjacent the second surface 114 of the second layer 102.

[0024] The first and third layers 101, 103 are preferably a white fleecematerial, although any suitable material might be used. Preferably, thewhite fleece material includes at least ten (10) percent fiberglass byweight. Typically, the white fleece material includes between sixty-five(65) and seventy (75) percent fiberglass by weight. More preferably, thefirst and third layers 101, 103 are made from a fiberglass mat withadhesive, such as MICROLITH® glass fiber mat available from JohnsManville, Corp., as Type SM-H 50/34 B51. This preferred materialcombines the first and fourth layers 101, 104 into one fiberglass matwith adhesive, and the third and fifth layers 103, 105 into onefiberglass mat with adhesive. The adhesive can be, for example, athermoplastic bonding agent.

[0025] The first and third layers 101, 103 are advantageous. Oneadvantage is that the first layer and third layers 101, 103 add strengthto the ceiling tile 10, which might otherwise sag under its own weight.The first and third layers 101, 103 also add a pleasing aestheticappearance to the ceiling tile 10 when it is installed.

[0026] While the example embodiment shown includes two layers 101, 103surrounding the second layer 102, it is possible to have only one layeron either side of the second layer 102. FIG. 5 illustrates anotherexample embodiment in which only one adjacent layer is used in a ceilingtile 200. Referring now to FIG. 5, if only one layer 220 is used, it ispreferably on a surface 212 of a second layer 210 oriented downwards asthe ceiling tile 200 is placed in the framework of the suspended ceilingdescribed previously herein. In this orientation, the layer 220 is intension and tends to keep the second layer 210 from sagging, and thelayer 220 also presents an aesthetically pleasing appearance. Of course,the ceiling tile 200 could also be oriented upwards, or in the reversedirection. The layer 220 is joined to the second layer 210 by anadhesive zone 230 therebetween. Of course, the layer 220 could be joinedto the second layer by chemical bonding.

[0027] Referring back to FIG. 4, the first and third layers 101, 103 arepreferably laminated to the second layer 102 by adhesive layers 104,105, respectively, between the first and third layers 101, 103 and thecorresponding surface 112, 114 to which they are attached. Preferably, ahot melt or pressure sensitive adhesive is used to join the first andthird layers 101, 103 to the second layer 102. The first and thirdlayers 101, 103 might also be attached to the second layer 102 bycoating or impregnating the first and third layers 101, 103 with ahot-melt adhesive.

[0028] The second layer 102, along with the first and third layers 101,103, is then run through a heated nip roller assembly, not shown. Theheated roller melts the adhesive on the first and third layers 101, 103as the arrangement passes through the nip roller, thus joining the firstand third layers 101, 103 to their respective surface 112, 114 of thesecond layer 102.

[0029] The ceiling tile of the present disclosure can be made thinnerthan a typical ceiling tile, due to its high strength and improvedacoustical properties. For example, a twenty-four (24) inch square tilecan be made 0.4 inches thick. The ceiling tile of the present disclosurecan also be made into tiles ranging from twenty-four (24) inches byforty-eight (48) inches up to forty-eight (48) inches by ninety-six (96)inches that are 0.6 inches thick. The tile can be made to otherdimensions in both thickness and length and width, and the exampledimensions are used to demonstrate the high strength of the ceiling tile10 of the present disclosure. The ceiling tile 10 of the presentdisclosure can be made as thin as 0.04 inches thick. The tiles generallyhave a first axis and a second axis, and the tile is typically longeralong the first axis than along the second axis. The first axis ispreferably between five (5) feet and eight (8) feet and the second axisis preferably between three (3) feet and four (4) feet.

[0030] The present invention should not be considered limited to theparticular examples described above, but rather should be understood tocover all aspects of the invention as fairly set out in the attachedclaims. Various modifications, equivalent processes, as well as numerousstructures to which the present invention may be applicable will bereadily apparent to those of skill in the art to which the presentinvention is directed upon review of the instant specification.

1. A ceiling tile comprising: a first layer having first and secondplanar surfaces; a second layer comprised of at least ten (10) percentfiberglass by weight joined adjacent the first planar surface.
 2. Theceiling tile of claim 1, further including a third layer comprised of atleast ten (10) percent fiberglass by weight joined adjacent the secondplanar surface.
 3. The ceiling tile of claim 2, further including afirst adhesive layer between the second layer and the first planarsurface and a second adhesive layer between the third layer and thesecond planar surface.
 4. The ceiling tile of claim 3, wherein theadhesive is a thermoplastic bonding agent.
 5. The ceiling tile of claim3, wherein the adhesive is a hot melt adhesive.
 6. The ceiling tile ofclaim 1, wherein the first layer comprises a foam core.
 7. The ceilingtile of claim 1, wherein the ceiling tile is less than 0.6 inches thick.8. The ceiling tile of claim 1, wherein the ceiling tile has a firstaxis and a second axis, wherein the first axis is between five (5) andeight (8) feet long and the second axis is between three (3) and four(4) feet long.
 9. The ceiling tile of claim 1, wherein the ceiling tilehas a first axis and a second axis, wherein the first axis is abouteight (8) feet long and the second axis is about four (4) feet long. 10.An acoustical ceiling tile comprising: a foam panel having first andsecond surfaces, the foam panel comprised of an open-cell melamine foam;and a first laminated layer impregnated with fiberglass and joined tothe first surface of the foam panel.
 11. The acoustical ceiling tile ofclaim 10, further including a second laminated layer impregnated withfiberglass and joined to the second surface of the foam panel.
 12. Theacoustical ceiling tile of claim 10, wherein the first laminated layeris joined to the first surface by an adhesive therebetween.
 13. Theacoustical tile of claim 11, wherein the second laminated layer isjoined to the second surface by an adhesive therebetween.
 14. Theacoustical tile of claim 13, wherein the adhesive is a hot melt or apressure sensitive adhesive.
 15. The ceiling tile of claim 10, whereinthe foam panel is less than 0.6 inches thick.
 16. The ceiling tile ofclaim 10, wherein the foam panel is about 0.4 inches thick.
 17. Theceiling tile of claim 10, wherein the foam panel has a first axis and asecond axis, wherein the first axis is between five (5) and eight (8)feet long and the second axis is between three (3) and four (4) feetlong.
 18. The ceiling tile of claim 10, wherein the foam panel has afirst axis and a second axis, wherein the first axis is about (eight) 8feet long and the second axis is about four (4) feet long.
 19. A ceilingtile comprising: two opposed layers surrounding a foam core made from anopen-cell melamine foam, the two opposed layers comprised of a materialhaving at least ten (10) percent fiberglass by weight.
 20. The ceilingtile of claim 19, wherein the two layers are joined to the foam corewith an adhesive layer therebetween.